US20110211940A1 - System and method for inspection of stator vanes - Google Patents
System and method for inspection of stator vanes Download PDFInfo
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- US20110211940A1 US20110211940A1 US12/714,207 US71420710A US2011211940A1 US 20110211940 A1 US20110211940 A1 US 20110211940A1 US 71420710 A US71420710 A US 71420710A US 2011211940 A1 US2011211940 A1 US 2011211940A1
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Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D21/00—Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for
- F01D21/003—Arrangements for testing or measuring
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
- F01D25/28—Supporting or mounting arrangements, e.g. for turbine casing
- F01D25/285—Temporary support structures, e.g. for testing, assembling, installing, repairing; Assembly methods using such structures
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/95—Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
- G01N21/954—Inspecting the inner surface of hollow bodies, e.g. bores
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2260/00—Function
- F05D2260/80—Diagnostics
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2270/00—Control
- F05D2270/80—Devices generating input signals, e.g. transducers, sensors, cameras or strain gauges
- F05D2270/804—Optical devices
- F05D2270/8041—Cameras
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
- G01N2021/8887—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges based on image processing techniques
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
Abstract
Description
- The subject matter disclosed herein relates to gas turbine engines and, more particularly, to inspection of interior components of such turbine engines.
- In general, gas turbine engines combust a mixture of compressed air and fuel to produce hot combustion gases. The combustion gases may flow through one or more turbine stages to generate power for a load and/or a compressor. The compressor may include rotary components, such as rotors and blades that rotate about a shaft, and stationary components, such as stator vanes. Over time, the various components of the compressor of the gas turbine engine may wear or develop defects. Inspection of these components to determine wear and/or defects may be difficult due to the enclosure of the gas turbine engine.
- One technique for inspecting internal components of the gas turbine engine may include inserting a borescope through borescope holes to manually inspect different components, such as rotor blades or stator vanes. Unfortunately, such inspections using a borescope are time consuming and labor intensive. Additionally, the field of view of the borescope is limited and may not provide complete inspection coverage of all internal components of the gas turbine engine. Further, the borescope lens may have limitations in the depth of field and resolution, thus making interpretations and qualification of the borescope images difficult and ambiguous. Other inspection procedures may require removal of the compressor housing and disassembly of the compressor to inspect internal components.
- In one embodiment, a method includes rotating an image recording assembly removably coupled to a rotary component of a compressor of a gas turbine engine around a shaft of the gas turbine engine and recording images of stationary components disposed circumferentially around the shaft, without removal of a housing of the compressor.
- In another embodiment, a system includes an image recording assembly for a compressor of a gas turbine. The image recording assembly includes an image recording device, a light source, a storage device and a coupling mechanism. The coupling mechanism couples the image recording system to a rotor blade of the compressor and the image recording device is oriented to record images of stator vanes of the compressor as the rotor blade rotates.
- In another embodiment, a method includes inserting an image recording assembly into a compressor housing of a gas turbine engine, coupling the image recording assembly to a rotor blade of a compressor of the gas turbine engine, and determining defects in an internal component of the compressor from images recorded by the image recording assembly.
- These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
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FIG. 1 is a schematic flow diagram of a gas turbine engine that may be inspected in accordance with an embodiment of the present invention; -
FIG. 2 is a sectional view of the compressor of the gas turbine engine ofFIG. 1 sectioned through the longitudinal axis in accordance with an embodiment of the present invention; -
FIG. 3 is a perspective view of a stage of the compressor of the gas turbine engine ofFIG. 1 in accordance with an embodiment of the present invention; -
FIG. 4 is a front view of the stage ofFIG. 3 with an image recording assembly in accordance with an embodiment of the present invention; -
FIG. 5 is a block diagram of an image recording assembly and an imaging processing system in accordance with an embodiment of the present invention; -
FIG. 6 is a block diagram of a stage of the compressor of the gas turbine engine having multiple cameras in accordance with an embodiment of the present invention; and -
FIG. 7 is a flowchart of a process for inspecting the compressor of a gas turbine engine using an image recording assembly in accordance with an embodiment of the present invention. - Embodiments of the invention include an inspection system to inspect internal components of a compressor of a gas turbine engine. The inspection system includes an image recording assembly having one or more image recording devices, light sources, storage devices, and power supplies. The image recording assembly may be inserted into a compressor without removal of the compressor housing or disassembly of the compressor. The image recording assembly may be removably coupled to a rotary component of the compressor, e.g., a rotor blade, and used to record images of stationary components, e.g., stator vanes, of the compressor. The image recording assembly may be removed from the compressor and the images may be provided to an image processing system for processing. The images may be inspected to identify wear and/or defects in the stationary components, e.g., stator vanes.
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FIG. 1 is a block diagram of anexemplary system 10 including agas turbine engine 12 that may be inspected using the inspection system described herein. In certain embodiments, thesystem 10 may include an aircraft, a watercraft, a locomotive, a power generation system, or combinations thereof. The illustratedgas turbine engine 12 includes anair intake section 16, acompressor 18, acombustor section 20, aturbine 22, and anexhaust section 24. Theturbine 22 is coupled to thecompressor 18 via ashaft 26. - As indicated by the arrows, air may enter the
gas turbine engine 12 through theintake section 16 and flow into thecompressor 18, which compresses the air prior to entry into thecombustor section 20. The illustratedcombustor section 20 includes acombustor housing 28 disposed concentrically or annularly about theshaft 26 between thecompressor 18 and theturbine 22. The compressed air from thecompressor 18 enters combustors 29 where the compressed air may mix and combust with fuel within the combustors 29 to drive theturbine 22. The combustion of the air and fuel may generate hot pressurized exhaust gases, which may then be utilized to drive one or more turbine blades within the turbine. - The
compressor 18 may includerotor blades 30 coupled to theshaft 26. Thecompressor blades 30 may span the radial gap between theshaft 24 and an inner wall orsurface 32 of acompressor housing 34 in which the internal components of the compressor are disposed. As used herein, theterm rotor blades 30 may also refer to “rotor buckets,” e.g., the rotor blade and various components. Thecompressor 18 may include a rotor that couples each of therotor blades 30 to theshaft 26. Thecompressor 18 may include stationary components, e.g.,stator vanes 36, extending from the inner wall orsurface 32 and axially offset from and adjacent to therotor blades 30. The rotation of theshaft 26 causes rotation of therotor blades 30, thereby drawing air into thecompressor 18 and compressing the air prior to entry into thecombustor section 20. -
FIG. 2 is a sectional view of thecompressor 18 of thegas turbine engine 12 ofFIG. 1 taken along the longitudinal axis 40. As depicted, thecompressor 18 may include multiplerotary stages 42. Each stage may include rotary components, such as arotor blades 30 coupled to a rotor that may be rotatably attached to the shaft 26 (FIG. 1 ). Theblades 30 may extend radially outward from the rotor and may be partially disposed within the path of the gases and between concentric portions ofstator vanes 36. Thestator vanes 36 may be arranged in a circumference around theshaft 26. - As described above with respect to
FIG. 1 , air may enter through theair intake section 16 and be compressed by thecompressor 18. The compressed air from thecompressor 18 may then be directed into thecombustor section 20 where the compressed air may be mixed with fuel gas. The mixture of compressed air and fuel gas is generally burned within thecombustor section 20 to generate high-temperature, high-pressure combustion gases, which may be used to generate torque within theturbine 22. - During operation of the
gas turbine engine 12, internal components of thecompressor 18 may develop wear and/or defects. For example, thestator vanes 36 may gradually wear or develop defects that affect efficiency and output of thecompressor 18. Such wear and defects may include, for example, cracks, corrosion, erosion, chipping, etc. In some embodiments, thegas turbine engine 12 may includeborescope holes 44 disposed longitudinally along thecompressor housing 34. Theborescope holes 44 may provide for conventional inspection of interior components via a borescope. A borescope may be inserted into one of theborescope holes 44, through thehousing 34 and theinner wall 32 of thecompressor 18, to examine thestator vanes 36 and other internal components of thecompressor 18. As described further below, theborescope holes 44 may provide access for an image recording assembly installed on therotor blades 30 and used to record images of thestator vanes 36. -
FIG. 3 is a perspective view of astage 42 of thecompressor 18.FIG. 3 further illustrates thestage 42 having arotor 46 withrotor blades 30 extending radially therefrom. Thestage 42 also shows thestator vanes 36 axially offset from and adjacent to therotor blades 30 and extending radially toward the axis of rotation of therotor 46. As seen inFIG. 3 , thestator vanes 36 extend circumferentially around the axis of rotation of therotor 46. As described below, embodiments of the present invention include image recording assemblies that may be secured to one ormore rotor blades 30 of thecompressor 18. The image recording assembly is secured to arotor blade 30 and oriented to record images of the stator vanes 36. Additionally, image recording assemblies may be removably coupled to rotor blades on the other side of thestator vanes 36 to provide further coverage of the stator vanes 36. In other embodiments, image recording assemblies may be coupled to the space between rotor blades. As therotor 46 rotates, the image recording assemblies also rotate around the axis of rotation, enabling the image recording device to record images of substantially all of thestator vanes 36 of thestage 42. -
FIG. 4 depicts a front view of astage 42 of thecompressor 18 in accordance with an embodiment of the present invention. For clarity, only onerotor blade 30 and threestator vanes 36 are illustrated inFIG. 4 . As shown inFIG. 4 , animage recording assembly 50 is secured to therotor blade 30. As described further below, theimage recording assembly 50 may include an image recording device, a light source, a storage device, a power supply, and a coupling mechanism. Theimage recording assembly 50 may be secured to any portion of therotor blade 30, andmultiple assemblies 50 may be removably coupled along the radial length of therotor blade 30. For example, as shown inFIG. 4 , theimage recording assembly 50 may be secured to therotor blade 30 near therotor 46. Thus, as therotor 46 rotates (such as in the direction illustrated by arrow 52), theimage recording assembly 50 rotates along the circumference ofstator vanes 36. As theimage recording assembly 50 rotates, theimage recording assembly 50 may record images of thestator vanes 36 in the field of view of the image recording device. Thus, as theimage recording assembly 50 rotates 360 degrees around the axis of rotation of therotor 46, images of all of the circumference ofstator vanes 36 may be recorded. -
FIG. 5 depicts a block diagram of theimage recording assembly 50 in accordance with an embodiment of the present invention. Theimage recording assembly 50 may include one or more image recording devices, e.g.,cameras 54, one or morelight sources 56, one or more storage devices 58 (e.g., non-volatile memory), one ormore power supplies 60, and acoupling mechanism 62. In one embodiment, theimage recording assembly 50 may have a length of approximately 100 mm, a width of approximately 7.5 mm, a thickness of about 4 mm, and a weight of approximately 50 g. Additionally,FIG. 5 depicts an image processing system 64 (e.g., a computer) having one ormore processors 66 and memory 68 (e.g., volatile or non-volatile memory). When removed from thecompressor 18, theimage recording assembly 54 may be coupled to theimage processing system 66 via acable 69. - The
image recording assembly 50 may include one camera oriented towards the stator vanes, or may include multiple cameras oriented in different directions. For example, thecameras 54 may be oriented to inspect the stator vanes of multiple stages on either side or therotor wheel 32. The number of cameras used to obtain substantially 100% image coverage of a stator vane may be determined from the height of the stator vane and the field of view of the camera. For example, for a stator vane of 27 cm and a field of view diameter of 110 mm, the number of cameras used to provide substantially 100% coverage of the stator vane is approximately 3 (270/110). - The
cameras 54 may include an analog camera and/or a digital camera and may receive power from the power supplies 60. In some embodiments, thecameras 54 may record images at a rate of at least about 2 frames-per-second (FPS) and may have a resolution of greater than at least 0.1 MP, 1 MP, 2 MP, or 3 MP. Thecameras 54 may include a time mechanism to enable the camera to record images periodically after a specified time interval. Additionally, or alternatively, thecameras 54 may include a trigger mechanism that may be activated by rotation of therotor blade 30. In some embodiments, thecameras 54 may include an OV9665FF camera and/or an OV2665AF camera manufactured by Supertech Optoelectronics of Taipei, Taiwan.. - In some embodiments, the
image recording assembly 50 may include a video recording device, so that theimage recording assembly 50 records video of the internal components of thecompressor 18. In other embodiments, theimage recording assembly 50 may include any other image sensing devices, such as infrared, ultrasound, and/or eddy current sensing devices. - The
light source 56 may include light emitting diodes (LEDs), fluorescent lights, incandescent lights, or any other suitable light device, and may be oriented to illuminate thestator vanes 36 or any other region capable of image record by thecameras 54. Multiple color light sources may be used, such as blue, green, red, white, or other colors. For example, blue LEDs may be used during a first portion of the inspection and green LEDS may be used during a second portion of the inspection. Thestorage device 58 may be a non-volatile memory device (e.g., a flash memory device) configured to provide a desired storage capacity and maintain the small size ofimage recording assembly 50. In one embodiment, the storage device may provide at least 2 GB, 4 GB, 6 GB, or 8 GB of memory. - In some embodiments, a
camera 54, alight source 56, and astorage device 56 may form an integrated assembly. In other embodiments acamera 54, alight source 56, and/or astorage device 58 may be individually selected and separately provided in theimage recording assembly 50. - The one or
more power supplies 60 may include one or more batteries, such as lithium ion, polymer lithium, nickel cadmium, or any other suitable batteries. In one embodiment, the power supplies 60 may include a battery having a capacity of at least about 250 mAh and a voltage of at least about 3 V. The power supplies 60 may be configured to provide for operation for thecamera 54, thelight source 56, and thestorage device 58 for at least the duration of the inspection process. - In one embodiment, the
image recording assembly 50 may include three pin-hole cameras (e.g., cameras having CCD or CMOS image sensors, such as an Exmor R back illuminated CMOS image sensor) oriented at 45 degrees, 0 degrees, and 45 degrees relative to the length of the rotor blade. Theimage recording assembly 50 may include multiple blue SMD LEDs, such that eachcamera 54 may be encircled by an arrangement of three LEDS. In such an embodiment, theimage recording assembly 50 may include an image processor, a memory, a battery, and a field programmable gate array (FPGA) to control and synchronize the subsystems of theassembly 50. Any or all of the above components may be mounted on a flexible printed circuit board (PCB) and disposed inside a housing. The housing may be coupled to the rotor blade using thecoupling mechanism 62 described in more detail below. The housing may also include a recessed portion or other feature to enable easier manipulation by a tool. - The
coupling mechanism 62 may be configured to provide enough force to secure theimage recording assembly 50 against the centrifugal force produced by therotating blade 30. For example, for animage recording assembly 50 having a weight of about 50 g, an image recording assembly placement of a radial distance of 500 mm from base of therotor blade 30, and a rotor speed of 1 rpm, the centrifugal force is approximately 0.0003 N. Thecoupling mechanism 62 may include a magnetic coupling, a clamping mechanism, an adhesive, a pneumatic mechanism, or any other suitable mechanism or combination thereof. - As mentioned above, in some embodiments the
coupling mechanism 62 may include a magnetic coupling. The magnetic coupling may be based on permanent magnets, electromagnets, or a pneumatic system. In one embodiment,coupling mechanism 62 may include rare earth permanent magnets with soft iron and brass components. The magnetic field produced by the magnets may be manipulated such that the coupling mechanism has an ON position (the magnetic field is directed outward from thecoupling mechanism 62 so thecamera assembly 50 can be coupled to a rotor blade) and an OFF position (the magnetic field is concealed inside thecoupling mechanism 62 so thecamera assembly 50 can be detached from a rotor blade). The manipulation of the magnetic field from the permanent magnets may be performed by a keepers, linear Halbach array, and electro-permanent magnets. - In other embodiments, the
coupling mechanism 62 may use an electromagnet having a soft iron core. In such an embodiment, current may be passed through the soft iron core to energize the electromagnet and couple thecamera assembly 50 to a rotor blade. In yet other embodiments, a pneumatic system may include an array of micro suction cups and a micro air pump to create a vacuum force and allow the suction cups to couple theimage recording assembly 50 to a rotor blade. - In some embodiments, actuation of any of the
coupling mechanisms 62 described above may be through a switch included in theimage recording assembly 50 and operable by a tool used to insert theimage recording assembly 50. For example, in one embodiment an actuation mechanism may include a motor (e.g., a DC or stepper motor) having a shaft attached to the operating mechanism of the coupling mechanism 62 (e.g., the permanent magnet mechanism, a switch for an electromagnet, a switch for a micro air pump, etc.). The actuation mechanism may include a collapsible switch configured to operate the motor, such that the collapsible switch may be collapsed to turn the motor OFF and may be released to turn the motor ON. The collapsible switch may include a spring to bias the switch to the released position. During insertion of theimage recording assembly 50, the collapsible switch may be collapsed via a tool (e.g., alligator clips) and then released when theimage recording assembly 50 is in position. Such a tool may also include a flexible cable, an image sensor, and an electromagnet, to enable easier viewing and manipulation of theimage recording assembly 50 when it is inserted into thecompressor 18. The electromagnet may secure theimage recording assembly 50 after release of the alligator clips to ensure secure coupling to the rotor blade. In one embodiment, the tool may include borescope tools available from GE Inspection Technologies of Lewistown, Pa. - In some embodiments, the
image recording assembly 50 may include awireless communication device 70 that may be used to transmit images from thecameras 54 and/orstorage devices 58 to theimage processing system 64. Alternatively, in other embodiments theimage recording assembly 50 may be physically connected to theimage processing system 64 via thecable 69, when theimage recording assembly 50 is removed from thegas turbine engine 12. For example, theimage recording assembly 50 may be coupled to theimage processing system 64 via a Universal Serial Bus (USB) interface, Firewire interface, eSata interface, or any other suitable interface. Theimage processing system 64 may also be capable of processing any data received from theimage recording assembly 50, such as still images, video, infrared images, ultrasound images, eddy current images, etc. -
FIG. 6 depicts a block view of acompressor stage 42 and inspection system in accordance with an embodiment of the present invention. As shown inFIG. 6 , arotor blade 30 is disposed betweenstator vanes 36 inside the inner wall or surface of the compressor. In the embodiments depicted inFIG. 6 ,multiple cameras 54, e.g., six cameras, are removably coupled to therotor blade 30. As noted above, themultiple cameras 54 may be included in a singleimage recording assembly 50 having multiple cameras or each of themultiple cameras 54 may be included in a respective one of multipleimage recording assemblies 50. Thecameras 54 may be oriented to provide substantially 100% image coverage of thestator vanes 36 adjacent to therotor blade 36. For example, as shown inFIG. 6 , each camera may be oriented in the directions indicated byarrows 72. As therotor blade 32 rotates, each camera may continuously or periodically record images of thestator vane 36 viewable from the camera's orientation. Multiple cameras 54 (or image recording assemblies 50) may be removably coupled to eachrotor blade 32 of thecompressor 18 to provide inspection of allstator vanes 36. Further, in some embodiments, inspection of a circumference ofstator vanes 36 may be accomplished by using cameras 54 (and image recording assemblies 50) onmultiple rotor blades 32, such that each camera 54 (and image recording assembly 50) records images from a portion of the circumference ofstator vanes 36. -
FIG. 7 depicts an embodiment of aprocess 80 for the inspection of the condition ofstator vanes 36 of thecompressor 18 of thegas turbine engine 12 using theimage recording assembly 50 described above. It should be appreciated that theprocess 80 may be performed during shutdown of thegas turbine engine 12 andcompressor 18, and thatprocess 80 may be performed without removal of thehousing 34 or disassembly of thecompressor 18. Initially, thecameras 54,light sources 56, andcoupling mechanism 62 may be assembled (block 82). Next, the power supplies 60 andstorage devices 58 may be assembled with thecameras 54,light sources 56, andcoupling assembly 62 to form the image recording assembly 50 (block 84). In some embodiments, each time theimage recording assembly 50 is used, only the power supplies 60 and/or thestorage devices 58 may be replaced (to ensure adequate power and/or storage for the inspection operation). Theimage recording assembly 50 may be powered on, and the operability of thecameras 54,light sources 56,storage devices 58, andpower supplies 60 may be verified (block 86). - The image recording assembly (or assemblies) 50 may be inserted into the
compressor 18 of thegas turbine engine 12 and removably coupled to a rotor blade of the compressor 18 (block 88). As described above, in some embodiments the image recording assembly (or assemblies) may be inserted into thecompressor 18 through aborescope hole 44. Additional holes may be manufactured in thecompressor 18 to allow for insertion of theimage recording assembly 50. In some embodiments, multiple image recording assemblies may be inserted intocompressor 18 and removably coupled to multiple rotor blades of a rotor. Alternatively, or additionally, multipleimage recording assemblies 50 may be inserted into thecompressor 18 and removably coupled to rotor blades of different rotor wheels of thecompressor 18. Theimage recording assembly 50 may be inserted into theborescope hole 44 using tools, such as a “gripper,” through a work channel attached to the borescope. As described above, such tools may include a flexible cable, alligator clips, and an electromagnet, and the alligator clips may be configured to release a collapsible switch to activate thecoupling mechanism 62 of theimage recording assembly 50. - After securing the
image recording assembly 50 to therotor blade 30, the turn gear operation of thecompressor 18 may be started (block 90). In some embodiments, the turn gear operation may be performed manually such that the shaft and rotors of thecompressor 18 are directly or indirectly rotated by a technician. In other embodiments, the turn gear operation may performed automatically by slow turning tools, a motor or other automated rotation of the rotary components of the compressor. - As the rotor wheels of the
compressor 18 rotate, the camera(s) 54 of the image recording assembly (or assemblies) 50 records images at periodic or rotational intervals (block 92). The image record may be based on a timer, such that the camera records an image after a duration of time. In other embodiments, the image record may be based on a trigger from the turn gear operation, such that the camera records an image after a specific degree of rotation. In one embodiment, an operator may activate thecoupling mechanism 62 by a switch at the borescope arm. Once theimage recording assembly 50 gets attached to therotor blade 30, the “gripper” opens and the operator can retrieve the borescope arm. The opening of the “gripper” triggers the switch which in turn triggers the recording device(s), e.g.,cameras 54, of theimage recording assembly 50. In another embodiment, a start/stop triggering mechanism may be synchronized with the key-phasor of theturbine 22. At a certain angular position of the key-phasor, the recording device, e.g.,cameras 54, may start recording the images. The location of the key-phasor may be determined using a proximity probe. As the key-phasor rotates by a certain angle, thecameras 54 may be triggered wirelessly. Thecameras 54 may stop recording as soon as the key-phasor returns back to its original position. - After image record is complete, the turn gear operation may be stopped (block 94). The image record may be complete after one, two, three, four, or more rotations of the image recording assembly around the circumferential arrangement of stator vanes.
- The image recording assembly (or assemblies) 50 may then be removed from the gas turbine engine 12 (block 96). As described above, in some embodiments, the image recording assembly (or assemblies) 50 may be removed through the
borescope hole 44 of thegas turbine engine 12. As noted above, the image recording assembly (or assemblies) 50 may be removed through theborescope hole 44 through the use of tools, e.g., a “gripper.” As described above, such tools may include a flexible cable, alligator clips, and an electromagnet, and the tools may be configured to activate a collapsible switch to deactivate thecoupling mechanism 62. The image recording assembly (or assemblies) 50 may be connected to theimage processing system 66 and images recorded by thecameras 54 may be downloaded from the storage devices 38 to the image processing system (block 88). For example, the image recording assembly (or assemblies) 50 may be coupled to theimage processing system 66 by acable 69. In other embodiments, the image recording assembly (or assemblies) 50 may include awireless communication device 70 that may provide for wireless downloading of images to the image processing system 66 (with or without removal of the image recording assembly (or assemblies) 50 from the compressor 18). Theimage processing system 66 may process the images recorded by thecameras 54 to provide for easier interpretation of the images and any wear and defects on the stator vanes shown in such images (block 100). Such image processing may include color channel splitting (e.g., RGB splitting), contrast enhancement, edge detection (e.g., Canny edge detection), magnification, or any other image processing. After processing the images, the images may be inspected (block 102). In some embodiments, the images may be manually inspected by a technician to identify wear and/or defects of the stator vanes or other internal components shown in the images. In other embodiments, theimage processing system 66 may automatically inspect the images to identify wear and/or detects, such as by looking for areas having certain attributes. Finally, the scan of other stages may continue using the same or additional image recording assemblies 50 (block 104). - Advantageously, the
inspection process 80 described above may provide increased coverage area of the inspection and inspection of the interior components of thegas turbine engine 12 without removal of the housing of thecompressor 12 or other components. The increased coverage area may increase the probability of detection of wear and/or defects in the stator vanes or other internal components recorded by the image recording assembly. Further, theinspection process 80 may be automated at various tasks, such as image record and image processing. Additionally, theinspection process 80 described above may be less time consuming and easier to perform than other inspection processes, thus increasing productivity and reducing inspection time. - This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
Claims (20)
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
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US12/714,207 US8602722B2 (en) | 2010-02-26 | 2010-02-26 | System and method for inspection of stator vanes |
JP2011031479A JP5681520B2 (en) | 2010-02-26 | 2011-02-17 | Stator vane inspection system and method |
EP11155693.2A EP2363575B1 (en) | 2010-02-26 | 2011-02-23 | System and method for inspection of stator vanes |
CN201110045578.5A CN102192914B (en) | 2010-02-26 | 2011-02-25 | System and method for inspection of stator vanes |
Applications Claiming Priority (1)
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US12/714,207 US8602722B2 (en) | 2010-02-26 | 2010-02-26 | System and method for inspection of stator vanes |
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US20110211940A1 true US20110211940A1 (en) | 2011-09-01 |
US8602722B2 US8602722B2 (en) | 2013-12-10 |
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US12/714,207 Active 2032-10-12 US8602722B2 (en) | 2010-02-26 | 2010-02-26 | System and method for inspection of stator vanes |
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US (1) | US8602722B2 (en) |
EP (1) | EP2363575B1 (en) |
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Also Published As
Publication number | Publication date |
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EP2363575B1 (en) | 2021-08-18 |
CN102192914B (en) | 2015-07-22 |
JP5681520B2 (en) | 2015-03-11 |
EP2363575A2 (en) | 2011-09-07 |
CN102192914A (en) | 2011-09-21 |
US8602722B2 (en) | 2013-12-10 |
EP2363575A3 (en) | 2017-04-19 |
JP2011179493A (en) | 2011-09-15 |
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